L-shaped sheet metal cooling jacket with stamped bearing support

ABSTRACT

An embodiment of an electric machine includes inner and outer housing sections attached to one another to form, at an axial end of the electric machine, a cooling channel therebetween. Such electric machine also includes a bearing carrier coupled to the housing sections and radially registered to the inside diameter of the inner housing section. An embodiment of an electric machine includes annular, L-shaped inner and outer sheet metal housing sections enclosing a cooling channel at an axial end of the electric machine and otherwise being substantially parallel and contiguous, and includes a first bearing assembly coupled to the inner housing section.

BACKGROUND

The present invention is directed to increasing performance andefficiency of an electric machine and, more particularly, to decreasingmachine size while improving the machine's heat rejection.

An electric machine is generally structured for operation as a motorand/or a generator, and may have electrical windings and/or permanentmagnets, for example in a rotor and/or in a stator. Heat is produced inthe windings and magnets, and by bearings or other sources of friction.Eddy currents and core losses occur. In a densely packed electricmachine operating at a high performance level, excessive heat may begenerated. Such heat must be removed to prevent it from reachingimpermissible levels that may cause damage and/or reduction inperformance or life of the motor.

Various apparatus and methods are known for removing heat. One exemplarymethod includes providing the electric machine with a water jackethaving fluid passages through which a cooling liquid, such as water, maybe circulated to remove heat. Another exemplary method may includeproviding an air flow, which may be assisted with a fan, through oracross the electric machine to promote cooling. A further exemplarymethod may include spraying or otherwise directing oil or other coolantdirectly onto end turns of a stator winding.

There is generally an ongoing need for increasing performance andefficiency of electric machines, such by providing more power in asmaller space. Although various structures and methods have beenemployed for housing and cooling an electric machine, improvementremains desirable.

SUMMARY

It is therefore desirable to obviate the above-mentioned disadvantagesby providing a machine construction that minimizes size and maximizesheat rejection to assure increased efficiency and reliability.

According to an exemplary embodiment, an electric machine includes innerand outer housing sections attached to one another to form, at an axialend of the electric machine, a cooling channel therebetween. Theelectric machine also includes a bearing carrier coupled to the housingsections and radially registered to the inside diameter of the innerhousing section.

According to another exemplary embodiment, an embodiment of an electricmachine includes annular, L-shaped inner and outer sheet metal housingsections enclosing a cooling channel at an axial end of the electricmachine and otherwise being substantially parallel and contiguous, andincludes a first bearing assembly coupled to the inner housing section.

The foregoing summary does not limit the invention, which is defined bythe attached claims. Similarly, neither the Title nor the Abstract is tobe taken as limiting in any way the scope of the claimed invention.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

The above-mentioned aspects of exemplary embodiments will become moreapparent and will be better understood by reference to the followingdescription of the embodiments taken in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a schematic view of an exemplary electric machine;

FIG. 2 and FIG. 3 are respective front and rear perspective views of anelectric machine, according to an exemplary embodiment;

FIG. 4A is a partial sectional perspective view and FIG. 4B is asectional elevation view of an electric machine, according to anexemplary embodiment;

FIG. 5A is a partial schematic elevation view and FIG. 5B is a topschematic view of an S-shaped coolant path formed by stamping the axialend of a housing section, according to an exemplary embodiment;

FIG. 6A is a schematic diagram of an exemplary DC/DC converter;

FIG. 6B is a schematic diagram of an exemplary DC/AC inverter;

FIG. 7 is a schematic top view of power electronics distributed on anaxial end of an electronic machine, according to an exemplaryembodiment;

FIG. 8 is a schematic elevation view taken along the line VIII-VIII ofFIG. 7;

FIG. 9 is a schematic perspective view of an exemplary spring assembly;

FIG. 10 is a schematic elevation view of electronic components beingaxially biased against a housing axial end surface, according to anexemplary embodiment;

FIG. 11 is a partial perspective view of power electronics componentsmounted to a substrate 124, according to an exemplary embodiment;

FIG. 12 is a partial schematic elevation view of power electronicscomponents being axially biased against an axial end cooling jacket by anumber of O-rings, according to an exemplary embodiment;

FIG. 13A is a schematic top view of housing axial end surface, and FIG.13B is a schematic top view of the axially inner portion of an endcover, according to an exemplary embodiment;

FIG. 14 is a perspective view and FIG. 15 is a schematic elevation viewof a power electronics module being clamped to a housing axial endsurface, according to an exemplary embodiment; and

FIG. 16 is a cross-sectional schematic view of an integrated coolantsystem, according to an exemplary embodiment.

Corresponding reference characters indicate corresponding or similarparts throughout the several views.

DETAILED DESCRIPTION

The embodiments described below are not intended to be exhaustive or tolimit the invention to the precise forms disclosed. Rather, theembodiments are chosen and described so that others skilled in the artmay appreciate and understand the principles and practices of theseteachings.

FIG. 1 is a schematic view of an exemplary electric machine 1 having astator 2 that includes stator windings 3 such as one or more coils. Anannular rotor body 4 may also contain windings and/or permanent magnetsand/or conductor bars such as those formed by a die-casting process.Rotor body 4 is part of a rotor that includes an output shaft 5supported by a front bearing assembly 6 and a rear bearing assembly 7.Bearing assemblies 6, 7 are secured to a housing 8. Typically, stator 2and rotor body 4 are essentially cylindrical in shape and are concentricwith a central longitudinal axis 9. Although rotor body 4 is shownradially inward of stator 2, rotor body 4 in various embodiments mayalternatively be formed radially outward of stator 2. Electric machine 1may be an induction motor/generator or other device. In an exemplaryembodiment, electric machine 1 may be a traction motor for a hybrid orelectric type vehicle. Housing 8 may have a plurality of fins (notshown) formed to be spaced from one another on a housing externalsurface for dissipating heat produced in the stator windings 3.

FIG. 2 and FIG. 3 are respective front and rear perspective views of anelectric machine 10, according to an exemplary embodiment. A firsthousing member 11 has an annular flanged portion 12 adapted for mountingelectric machine 10, for example in an electric vehicle. The axiallyextending portion of first housing member 11 is covered by a secondhousing member 13. An annular flange portion 14 of housing member 13 isformed to be contiguous with flange 12. A front cover 15 has an axialend portion and has an axially extending portion that is enclosed byhousing members 11, 13. A pulley 16 is attached to a drive shaft 17 witha nut 18 or other fastening structure. A rear cover 19 is secured to therear axial end of electric machine 10 with bolts 20 or other suitablefastening structure. A coolant input tube 21 and a coolant output tube22 extend from an interior coolant system through rear cover 19. Housingsections 11, 13 may each be formed of sheet metal that is stamped intoshape. For example, housing member 13 may be formed as a single sheetthat is wrapped around housing member 11 and joined together at a seam23. Although described with pulley 16, a given embodiment mayalternatively utilize a female spline formed in shaft 5 instead of apulley. Outer housing section 13 includes baffles 233, 234, discussedbelow.

FIG. 4A is a partial sectional perspective view and FIG. 4B is asectional elevation view of an exemplary electric machine 10. Housingsections 11, 13 may be sheet metal components each having an “L” shapedprofile. Housing sections 11, 13 are formed to have a substantially sameannular shape so that when they are attached together they effect anannular housing configuration having one or more coolingchannels/jackets 35 between portions of the two housing sections 11, 13.For example, inner housing section 11 may be attached to outer housingsection 13 by any appropriate process, such as by brazing, soldering,welding, crimping, bolting, staking, using adhesives, sealant, and/orgaskets, or by other operations. The axially extending portion 36 ofhousing section 11 is attached to the axially extending portion 37 ofhousing section 13.

Coolant may be circulated through one or more channels/cavities 35formed between housing sections 11, 13. For example, attached portionsof housing sections 11, 13 that enclose cooling channels 35 act ascoolant seals that prevent leakage from such coolant channels 35.Individual channels 35 may be joined together in any series or parallelarrangement. A channel 35 may have baffles formed by stamping a bafflepattern into one or both of housing sections 11, 13. For example, outerhousing section 13 may have features embossed therein that cause theflowing coolant to circulate in an “S” shaped pattern. The coolant flowmay be distributed through both portions of the “L” shaped sheet metalconstruction (e.g., the axially and radially extending portions).Alternatively, baffles may be provided as a separate structure insertedinto a given coolant channel 35. In various embodiments, the embossmentsmay be created to cause the flowing coolant to circulate in otherpatterns, such as circumferentially on both an axial end as well as inthe radial portion of the housing circumscribing stator 2. As therespective short legs of the “L” shape, radially extending portions 201,202 are joined together in areas surrounding channels 35, therebyforming boundaries to contain the coolant in axial end cooling channels35. Cooling channel(s) 35 may be fluidly connected to a cooling jacket200 circumscribing stator 2.

In an exemplary embodiment, power electronics 30 are assembled intocover 19 before installing the electronics/cover assembly directly tothe rear axial end of machine 10. For example, electronics 30 may have aheat transfer surface 31 mounted to an axially inward surface 29 of endcover 19. Alternatively, power electronics 30 may be mounted to housingsurface 33 and cover 19 later attached. As the respective long legs ofthe “L” shape, the axially extending portion 36 of housing section 11 isattached to the axially extending portion 37 of housing section 13.

Front cover 15 has an annular inner axially extending portion 24 and anannular inner radially extending portion 25 structured for securing afront bearing assembly 26 having a rotating portion fitted to shaft 17.At a radially outer periphery, front cover 15 has an annular, axiallyextending rim 199 fitted within axially extending portion 36 of housingsection 11. A rotor core 27 is secured to a middle portion of shaft 17and the rotating portion of a rear bearing assembly 28 is secured to therear portion of shaft 17. Rear cover 19 houses and protects powerelectronics 30 of electric machine 10. Rear cover 19 may be formed ofaluminum, steel, plastic, or any of a variety of composite materials,and may be attached to the rear axial end of electric machine 10 byfasteners 20 or by other suitable attachment structure. Inner housingsection 11 has an annular inner axially extending portion 203 and anannular inner radially extending portion 204 structured for securing arear bearing assembly 28 having a rotating portion fitted to shaft 17.In various embodiments, a separate bearing carrier (not shown) may beused in one or more bearing assemblies therein, and/or additionalmaterial thickness, welds, or other structure may be added to anotherwise consistent material of cover 15 and/or inner housing 11,respecting portions where additional material strength is required forproviding stable and reliable support of respective bearing assemblies26, 28. For example, a weld bead or the like may be placed at the apex232 of cover 15. In various embodiments, the bearing support portion ofhousing section 11 together with bearing assembly 28 may constitute acomplete bearing carrier. In particular, support structure for bearingsmay include housing section 11, in whole or in part. Alternatively, aseparate bearing carrier may be used at any bearing location, and mayinclude bearings, seals, grease fittings, and at least some supportstructure.

Bearing assemblies 26, 28 may take any appropriate form for a givenapplication and are described herein by example to include any bearingsrotationally supporting the axially-directed shaft 5. Structure ofannular bearing supports for assemblies 26, 28 is formed integrally inthe stamping of sheet metal portions 11, 13 that define a motor caseenclosing stator assembly 2 and rotor assembly 4. For example, ballbearings may be held in a bearing carrier configured to be radiallyand/or axially registered/aligned with housing 11 and/or stator assembly2. In an exemplary embodiment, sheet metal having a nominal thickness of2-3 mm may be used for forming bearing supports. Shape and compositionof materials at the apex of the “L” portion, and in axially extendingportion 203 and/or radially extending housing portion 204, may bemodified to provide additional strength in securing bearing assembly 28,in forming one or more keys or other structure (not shown) forpreventing relative rotation of the non-rotating portion of bearingassembly 28, for mechanically directing the heat flow in the vicinity ofbearing assembly 28, for integration of a coolant channel through or inproximity to a bearing assembly 28, for transferring information such asa temperature sensor signal through or in proximity to bearing assembly28, and/or for implementing/accommodating various other structure. Forexample, a hole (not shown) may be formed through an otherwisecontinuous annular structure of axially extending portion 203.Structural portions may be thermally matched, for example by havingcomponents with a same or similar coefficient of thermal expansion.

Bearing assemblies 26, 28 may include self-aligning bearings, ballbearings, journal bearings, magnetic bearings, hybrid devices, andothers. Alignment of bearing assemblies may be controlled back to acommon datum structure. For example, bearing assembly 28 may be machinedin position relative to a register diameter (e.g., inside diameter (ID))in front of a machine's inner housing. In such a case, a bearing carrieris pressed into the register diameter. Press fit conditions andtolerances are tightly controlled. Bearing assemblies 26, 28 andcorresponding support structure, such as axially extending housingportion 203, may be formed of a non-electrically conductive material toact as insulators against eddy currents that may otherwise lower machineefficiency. For example, bearing assemblies and bearing supports mayconduct magnetic flux and/or voltage that may result in damage orreduced performance; to prevent such an occurrence, current insulatedbearings may be used, including hybrid bearings with ceramic rollingelements and inner or outer rings coated with oxide ceramics.

Bearing assemblies 26, 28 and corresponding support structure mayinclude additional components (not shown) such as washers, snap rings,and others, for maintaining radial alignment of bearing assemblies 26,28 relative to stator assembly 2 and housing sections 11, 13. A chosentype of bearing for a given application may require use of suchadditional structure for dampening and noise reduction, for cooling, forlubrication, for heat transfer, for strength, and for other purposes.Bearing assemblies 26, 28 may include bearing carriers, shock/vibrationcushioning structure such as rubber washers, axially elongated bushingsand spacers, coolant cavities, elastic supports, coolant seals andfittings, and other apparatus.

An annular sensor wheel 227 is secured to shaft 17 and a correspondingannular sensor pickup 228 is positioned to detect movement of sensorwheel 227. For example, wheel 227 may contain elements such as coil(s),magnet(s) or teeth (not shown) that may be detected by a transformer,Hall effect device, or other circuit. Together, wheel 227 and pickup 228may form a resolver system that outputs an electrical angle θcorresponding to a detected mechanical angle of shaft 5. Informationobtained by such resolver system may be used, for example in cooperationwith an engine management unit (EMU) or other ancillary circuitry, todetermine shaft speed, torque, phase, and various other parametersrelated to control of electric machine 1. Control functions may beoptimized to increase operational efficiency of electric machine 1and/or to increase safety and efficiency of a host vehicle. In variousembodiments, a system including wheel 227 and detector 228 may be formedas a rotary/pulse encoder and decoder, or a phase/speed detector systemmay include a resolver-to-digital converter. Electrical connections (notshown) to/from pickup 228 may be incorporated into an annular conduit229 and/or fed through cover 19. Fluid connections (if applicable) maybe contained in an axial end space 230 and/or within an annular recessspace 231.

FIG. 5A is a partial schematic elevation view and FIG. 5B is a topschematic view of an S-shaped coolant path formed by stamping the axialend of housing section 13, according to an exemplary embodiment.Embossments 222 are formed as stamped features that form baffles 223 ina coolant channel 224 that forms an S shape as it extendscircumferentially around the axial end of housing section 13. Forexample, embossments 222 may be formed so that axially inward surfaces225 of housing section 13 are attached to axially outward surface 226 ofhousing section 11, such as by resistance welding or other process. Inthe illustrated example, coolant channel 224 is a serial fluid channelbetween coolant inlet 21 and outlet 22. However, coolant channel 224 maybe formed in any appropriate serial/parallel configuration by beingjoined to other coolant channels, such as a stator cooling jacket,serpentine cooling insert, or other coolant passageway.

With reference to FIG. 4B, a thermal interface material (TIM) 32 havinga high thermal conductivity may be applied between surfaces 29, 31and/or between surfaces 33, 34 to reduce thermal resistance therebetweenand thereby improve operational efficiency. TIM 32 may be formulated asan adhesive, as a grease, and/or as a tape for bonding power electronics30 to cover surface 29 and/or to housing surface 33. In an exemplaryalternative embodiment, TIM 32 is applied to housing surface 33; powerelectronics 30 are then positioned and assembled onto end surface 33 ofhousing 13 prior to making all necessary electrical connections betweenpower electronics 30 and electric machine 10. For example, TIM 32 may beapplied between housing end surface 33 and a heat transfer surface 34 ofpower electronics 30; after assembling, connecting, and mountingelectronics 30 to surface 33, rear cover 19 is then installed. Inanother exemplary embodiment, TIM 32 is applied to surfaces 32, 34 priorto placing power electronics 30 onto housing surface 33. For example,TIM 32 applied to heat transfer surface 34 may be formulated as aquick-cure adhesive and TIM 32 applied to electronics surface 31 may beformulated as a grease, so that power electronics 30 is securely bondedto housing 13 but only has a thermal bond with cover 19. Regardless ofthe chosen application method, TIM 32 may be applied between powerelectronics 30 and cooling channel/jacket 35, thereby improving heattransfer from power electronics 30 to the coolant flow and maximizingoperational efficiency of electric machine 1.

TIM 32 may have a thermal conductivity of 1 to 20 W/m·K, a thickness of0.002 to 3.5 mm, and a maximum temperature rating of 200° to over 350°C. The TIM may be used without a hardener and associated curing, or ahardener may be mixed with the TIM before applying it. For example, TIM32 may be a non-curable liquid having a paste-like consistency, or itmay contain epoxy or another adhesive with a short curing time. Theviscosity of TIM 32 may be adjusted to optimize flow and removal of airduring assembly. When the TIM application process is optimized, a thinlayer of TIM fills air gaps created by surface irregularities, so thatsubstantially all air is removed from a corresponding interface and isreplaced with TIM. The application of TIM greatly reduces thermalresistance and thereby improves thermal transfer between powerelectronics 30 and housing 13/cooling jacket 35. In particular, air gapswithin power electronics 30 and at interfaces between surfaces 29, 31and/or between surfaces 33, 34 are removed. By reducing the thermalresistance within power electronics 30 and at its thermal interfaces,additional heat can be dissipated from an electric machine 1, which canoperate at a cooler temperature.

Subsequent processing may include removing excess TIM that has beensqueezed out of the interfaces, at least partially curing the TIM,and/or applying sealant at edges of TIM thermal interfaces. For example,certain TIM compositions having a high thermal conductivity do not cure,but remain in a semi-liquid state as a paste. To prevent migration ofsuch TIM over time, for example due to vibration, a bead of epoxy orother sealant may be provided at lateral edges of the TIM. For example,an exposed bead may result from excess TIM being pushed out of thermalinterfaces by an assembly process. When the TIM does not fully cure, orwhen reliability may be affected by centrifugal forces pushing the TIMradially outward over time, any excess TIM is removed and a curableepoxy or the like may then be applied for sealing the TIM inside thermalinterfaces. Seals may alternatively include O-rings, gaskets, resin,fiber, and/or structural barriers that block any exit paths out ofthermal interfaces. In some applications, such sealing may be effectedby use of a temporary gasket that is only required during themanufacturing process.

Some TIM may be partially or fully cured by being mixed with a hardener.Typically such curing takes approximately two hours at room temperatureand approximately five minutes at an elevated temperature such as 100°C. When TIM has a high viscosity and no migration, the absence ofthermal epoxies or other hardeners may reduce shrinkage and similarreliability issues. Depending on a particular application, TIM maycontain silicone, alumina or other metal oxides, binding agents, epoxy,and/or other material. The TIM has a high thermal conductivity and ahigh thermal stability, and may be formulated to have minimalevaporation, hardening, melting, separation, migration, or loss ofadhesion. Suitable materials are available from TIMTRONICS.

A biasing member 40 (e.g., FIG. 4B) may be placed between electronicssurface 31 and cover surface 29. For example, biasing member 40 may be aconventional metal spring, one or more Belleville springs, one or morespring members having a semi-rigid component, an array of springmembers, an O-ring, rubber or other flexible substance, a resilientdeformable structure, or other structure, whereby power electronics 30are axially pushed against housing surface 33. In an alternativeembodiment, biasing member 40 may be a clamp structured for axiallypulling power electronics 30 toward housing surface 33. In either case,the contact resistance between housing 13 and power electronics 30 isreduced by axially biasing respective surfaces 33, 34 toward oneanother. Biasing member 40 may be distributed in the circumferential,radial, and/or axial direction. For example, power electronics 30 mayinclude any number of individual components having various correspondinglengths, widths, and heights. In such a case, the structure of biasingmember 40 may be optimized for applying an even and consistent amount ofaxial force to the components.

FIG. 6A is a schematic diagram of an exemplary DC/DC converter 41 thatmay form a part of power electronics 30. DC/DC converter 41 includes apower switching section with two dual insulated gate bipolar transistor(IGBT) legs 38, 39 each having two IGBTs 42 and 43, and 44 and 46,respectively. The two legs 38, 39 are interconnected at midpoints by aswitching inductor (or switching inductors, as described below) 48having an inductance. Converter 41 also includes a first filter 50connected to the positive rail of the first IGBT leg 39 and a secondfilter 52 connected to the positive rail of the second IGBT leg 38. Asshown, filters 50, 52 include a first inductor 54, a first capacitor 56,a second inductor 58, and a second capacitor 60, respectively. DC/DCconverter 41 may also include a controller (not shown) within associatedvehicle electronics such as an engine control module (ECM). Powerelectronics 30 may also include one or more power modules (not shown) ina structure for mounting at housing end surface 33.

FIG. 6B is a schematic diagram of an exemplary DC/AC inverter 45.Inverter 45 includes a three-phase circuit coupled to stator coils 3.Inverter 45 includes a switch network having a first input coupled to avoltage source 62 (e.g., a battery 47 and/or an output 49 of DC/DCconverter 41). Although a single voltage source is shown, a distributeddirect current (DC) link with two series voltage sources or otherconfiguration may be used. The switch network comprises three pairs ofseries switches (e.g., IGBTs) with antiparallel diodes (i.e.,antiparallel to each switch) corresponding to each of the phases. Eachof the pairs of series switches comprises a first switch, or transistor,(i.e., a “high” switch) 64, 66, and 68 having a first terminal coupledto a positive electrode of the voltage source 62 and a second switch(i.e., a “low” switch) 70, 72, and 74 having a second terminal coupledto a negative electrode of the voltage source 62 and having a firstterminal coupled to a second terminal of the respective first switch 64,66, and 68. DC/DC converter 41 and inverter 45 may also include aplurality of power module devices, each including a semiconductorsubstrate or electronic die with an integrated circuit formed thereon.In operation, power electronics 30 must be kept below a temperature of125° C., whereas other components of electric machine 1 (e.g., statorwindings 3) may be able to withstand temperatures of 200° C. or more.Power electronics 30 may be distributed in a circumferential, radial,and/or axial direction, and may interface with various sensors andautomotive control modules, or ECMs, such as a controller for DC/DCconverter 41, an inverter control module, a vehicle controller, andother ancillary devices and components. For example, temperature orrotational speed sensors may be adapted to occupy a same generallocation at an axial end of electric machine 1. In another example, anyof power electronics components, stator ID cooling channels, gearreduction systems, clutches, and other structure may be placed inotherwise unused spaces such as the axially extending space surroundingthe respective circumferential perimeters of bearing assemblies 26, 28(e.g., FIG. 4A).

FIG. 7 is a schematic top view of power electronics distributed on anaxial end of an electronic machine, according to an exemplaryembodiment. Axial end surface 33 of housing 13 may be substantiallyplanar to provide a single flat mounting surface for various componentsof power electronics 30, or surface 33 may be formed with any number ofindividual component mounting surfaces each having a particular shape,axial height, radial width, and circumferential length. In theillustrated example, power electronics 30 include a first module 51having a width 53 and a length 55, a second module 57 having anirregular shape, a third module 59 having a width 61 and a length 63,and a fourth module having a width 67 and a length 69. Fluid inlet 21and fluid outlet 22 pass through axial end surface 33. Modules 51, 57,59, 65 have axial biasing locations that engage biasing members 40 (FIG.4B). For example, module 51 has spring engagement locations 71, 73adapted for being coupled to a spring member such as a conventionalmetal coil spring or leaf spring. Module 57 also has a spring engagementlocation 75. Module 59 has an axial biasing location 76 adapted forreceiving a spring-loaded plate that evenly distributes axial biasingforce so that module 59 has a corresponding uniform heat distribution.Module 65 has an axial biasing location 77 adapted for engaging arelatively long biasing member 40 such as a narrow strip of rubber.Module 51 interconnects with a multiple conductor wire assembly 78 forreceiving and sending respective input and output electrical signals andfor implementing electrical power connections. Wire assembly 78 mayinclude one or more electrical connectors 79 for electrical connectionto external devices such as a battery 47 (FIG. 4B). Module 51 and module57 are electrically connected by an interconnect 80, module 57 andmodule 59 are electrically connected to one another via an interconnect81, and module 59 is electrically connected to module 65 viainterconnect 82. Interconnects 80-82 may each have any number ofindividual conductors respectively sized for passing a predeterminedamount of current therethrough. For example, an individual conductorpassing a small level signal may be implemented as part of a printedcircuit board (PCB), and a high power conductor may be implemented as asuitable AWG copper wire or metal bar. Common materials having suitabletemperature and reliability characteristics may be used for forming aPCB and, typically, type FR-4 or ceramic based materials are preferred.Any of modules 51, 57, 59, 65 may include electrical conductors orientedto pass axially through housing surface 33. For example, module 65 mayinclude a metal bar type connector 83 that passes through surface 33 viaa feed-through hole 84, and may pass any number of other conductors toan axially inner side of housing 13 via feed-through holes 85, 86.Module 51 is positioned directly on top of three feed-through holes 87allowing, for example, leads of individual electronic components to passdirectly through surface 33 without being attached to a separateconductor. Any of modules 51, 57, 59, 65 may be electrically connectedto ancillary components/modules 88 that are physically independent ofaxial biasing. Similarly, any number of electrically independentcomponents/modules 89 may be axially biased and contained within spaceprovided along housing surface 33. For example, module 89 may be athermocouple having an axial biasing location 90 and an electrical cable91.

FIG. 8 is a schematic elevation view taken along the line VIII-VIII ofFIG. 7. Electronics module 89 and electronics module 57 have respectiveheat transfer surfaces 92, 93 placed onto housing surface 33, eitherdirectly or with a layer of TIM interposed therebetween. Axial biasingspace 94 contains a conventional metal coil spring 95 having oppositeaxial ends respectively engaged with inner end cover surface 29 and withan axially outward biasing surface 96 of module 89. Axial biasing space97 contains a conventional metal coil spring 98 having opposite axialends respectively engaged with inner end cover surface 29 and with aplate 99 adapted for being coupled to spring 98. Plate 99 couples spring98 to an axially outward biasing surface 100 of module 57. Module 57 hassurfaces such as surface 101 with various axial heights, and suchsurfaces may each have any number of axial biasing locations.

FIG. 9 is a schematic perspective view of an exemplary spring assembly102. A conventional metal coil spring 98 is mated to a plate 99 so thatspring assembly 102 may provide biasing in an axial direction 103. Inany embodiment, spring 98 or other biasing member may be secured to anaxial end of housing 13 or to any other structure by embossing a featurethat allows spring 98 to nest into its proper position. Alternatively,spring 98 may be soldered or brazed in place.

FIG. 10 is a schematic elevation view of electronic components beingaxially biased against a housing axial end surface, according to anexemplary embodiment. Power electronics modules 104, 105 each have twocomponent leads 108, 109 extending axially away from the respectivecomponent bodies. Leads 108, 109 may terminate in a substrate 110 orthey may be electrically connected to other components of powerelectronics 30 by another route such as in an enclosed space 111 withincover 19. When PCB 110 is used, spacers (not shown) or other structuremay be provided in an intermediate space 112 for assuring thatelectrical conductors of substrate 110 do not become shorted to axiallyinward cover surface 29. Components of modules 104, 105 may include oneor more passive devices such as inductors, high-temperature capacitors,and/or resistors, and one or more active devices such as diodes andtransistors. A module component may generate heat and/or may requirecooling to operate correctly and avoid heat-related damage such as thatcaused by melting. A leaf spring 113 has a biasing surface 114 thataxially presses against modules' surfaces 115, 116. Modules 104, 105have corresponding heat transfer surfaces 106, 107 that are therebybiased against housing axial end surface 33. The interface betweenhousing sections 11, 13 has contiguous and sealed portions surroundingfluid channel portions 117. For example, fluid channels 117 may beformed between the sheet metal of sections 11, 13 in locations thatunderlie power electronics components such as modules 104, 105. As aresult, thermal resistance between heat transfer surfaces 106, 107 andfluid channel 117 is reduced by the spring biasing of surfaces 106, 107against housing surface 33, so that transfer of heat between modules104, 105 and coolant passage 117 is improved. Leaf spring 113 may besecured to cover 19 by one or more attachment devices 118. For example,attachment device(s) 118 may include a rivet or other structure havingan attachment portion 119 that engages spring 113, such as bymetal-to-metal mating structure (e.g., washer having prongs), byseparate spring structure such as a conical or Belleville typespring/washer, by compression attachment such as riveting, by a lockingstructure such as a key, or by other structure. A biasing adjustmentdevice 120 such as a bolt or other structure may be provided for axialadjustment of tensioning force being exerted onto modules 105, 106. Forexample, adjustment device 120 may be threaded into an insulated nut 121that is forced axially inward when adjustment device 120 is tightened.The axially inward placement of nut 121 increases the axial force ofspring 113 and the corresponding urging of module surfaces 106, 107against the cooling jacket formed by the portion of housing 13 thatencloses channel 117. A lateral securement member 122 may be formed as apart of cover 19 and/or as an integral portion of leaf spring 113. Forexample, lateral securement member 122 may include a bore 123 structuredfor allowing an insertion machine to grasp or otherwise handle leafspring 113 for placement thereof, and lateral securement member 122 mayalso be structured for receiving a retaining rod (not shown) or otherpart of an adjacent mating structure, thereby providing additionalfixing of spring 113 to cover 19.

FIG. 11 is a partial perspective view of power electronics componentsmounted to a substrate 124, according to an exemplary embodiment. Powerelectronic components include a capacitor 125 and transistors 126-128.Substrate 124 may be a printed circuit board having a curved shape and awidth that permits installation of substrate 124 within cover 19 (FIG.4B). Capacitor 125 has a heat transfer surface 129, and transistors126-128 have respective heat transfer surfaces 130-132, withcorresponding heat sink structure. In an exemplary embodiment, heattransfer surfaces 129-132 are substantially coplanar, whereby whenloaded substrate 124 is mounted onto housing end surface 33, heattransfer surfaces 129-132 are flush with housing surface 33 eitherdirectly or with a layer of TIM interposed therebetween. Componentheights may be adjusted using spacers 133. Substrate 124 may haveelectronic components mounted on both sides thereof, and it may includeany number of through holes for passing a conductor or componentmounting structure therethrough. Cable connectors 134, 135, 136 arefixedly mounted on substrate 124 and respectively receive and terminateelectrical conductors therein. Such electrical conductors may passthrough substrate 124. In an exemplary embodiment, components 125-128and connectors 134-136 are installed into substrate 124. Cables (notshown) are fed through holes in end cover 19 and secured to connectors134-136, and then heat transfer surfaces 129-132 are coated with TIM andpositioned on housing end surface 33. A number of springs are affixed toaxially inner surface 29 of cover 19, and cover 19 is secured to housingsection 13 with bolts 20 (FIG. 4B) that mate with corresponding nuts137. As a result, the springs attached to cover 19 engage correspondingspring engagement locations (e.g., FIG. 7), including spring engagementlocations on the underside of substrate 124, whereby heat transfersurfaces 129-132 are axially biased against housing surface 33.

FIG. 12 is a partial schematic elevation view of power electronicscomponents being axially biased against an axial end cooling jacket by anumber of O-rings, according to an exemplary embodiment. Electroniccomponents including power electronics modules 138, 139, 140 andperipheral components 141, 142 are mounted on a substrate 124. Forexample, peripheral components 141, 142 may include electronics and/orconnectors that do not require a high degree of heat transfer. Powerelectronics modules 138-140 have respective heat transfer surfaces143-145 that are coplanar. Module 139 is coupled to or integrally formedwith a heat sink 146. Module 138 is axially offset from the top surface147 of substrate 124 with spacers 148, whereby heat transfer surface 143is made to be coplanar with heat transfer surfaces 144, 145. ThreeO-rings 149-151 are placed on the axially outward side of substrate 124,underneath respective power electronics modules 138-140. A spacer 152 isprovided between O-ring 151 and substrate 124 when the thickness oranother dimension of O-ring 151 necessitates adding another layer. Forexample, when thickness of O-ring 151 is small because of thedesirability of balancing the distribution of spring forces in the areaof O-ring 151, it may be necessary to utilize different sized O-rings151 and spacers 152 to provide a stable structure. O-ring 149 has adiameter D1, O-ring 150 has a diameter D2, and O-ring 151 has a diameterD3, the diameters D1-D3 being chosen to provide spring force to axiallyurge power electronics modules 138-140 against housing axial end surface33. Inner housing section 11 and outer housing section 13 are joinedtogether in some overlapping areas, for example being sealingly coupledtogether by welding, brazing, use of adhesives and sealants, and byother structure. In specific locations adjacent power electronicscomponents, inner housing section 11 and outer housing section 13 formcoolant channels and chambers therebetween. For example, a coolantchannel 153 and a coolant channel 154 are formed between housingsections 11, 13 to be respectively adjacent power electronics modules138-140. End cover 19 may have O-ring positioning/retaining projections155-157 formed on inner cover surface 29 for respectively retainingO-rings 149-151 during assembly. When cover 19 is secured to housingsections 11, 13, heat transfer surfaces 143-145 are contiguous withhousing surface 33 and are axially urged against surface 33 by springforce created by the compression of O-rings 149-151. An electricallynon-conductive material having a high thermal conductivity, such asthermally conductive potting compound, may be injected to fill spaces158 between cover 19 and housing 13, thereby improving heat transfer.For example, the top of substrate 124 may be filled with pottingmaterial so that only heat transfer surfaces 143-145 are exposed, andspace between substrate 124 and cover surface 29 may be masked off sothat the added potting material does not affect the desired springaction.

FIG. 13A is a schematic top view of housing axial end surface 33, andFIG. 13B is a schematic top view of the axially inner portion of cover19, according to an exemplary embodiment. Coolant inlet 21 receivescoolant flow from an external source such as a heat exchanger (notshown). The coolant passes through channels and cavities formed betweensheet metal housing sections 11, 13. An axial end, multiple section,baffled cooling jacket is thereby formed for cooling power electronicscomponents contained within the axial end of electric motor/generator 1.A channel 159 transfers the coolant from inlet 21 to a chamber 160having baffles 161 that guide the coolant in a predetermined paththrough chamber 160. The coolant passes from chamber 160 into a channel162 that empties into a chamber 163 having baffles 164. Baffles 164guide the coolant through an “S” shaped path that acts to maximize thetransfer of heat by slowing the coolant flow. Chamber 163 passes thecoolant to a chamber 166 via a channel 165 formed therebetween. Chamber166 includes baffles 167 that circulate the coolant in an “S” patternwithin chamber 166. The coolant exits chamber 166 through an outletpassage 168 that transfers the coolant to other portions of electricmachine 1, for example to a stator cooling jacket and/or to a nozzlesystem for spraying conductor end turn portions of stator coils 3 (FIG.1). In a typical system, the hot coolant is collected in a sump area(not shown) of electric machine 1 and may then be cooled in a heatexchanger such as an oil radiator before being returned to coolant inlet21.

FIG. 13B schematically shows the inside of cover 19. O-rings 169-173 areplaced onto inside cover surface 29 at predetermined locations. Powerelectronics modules 174-176 have respective heat transfer surfaces178-180 and are interconnected, electrically connected, and attached tocover 19 by attachment members 177 structured to retain modules 174-176without encumbering movement of O-rings 169-173 and without interferingwith a coplanar contiguous engagement of heat transfer surfaces 178-180with housing axial end surface 33. Holes 181, 182 are provided in theaxial end of cover 19 for receiving coolant inlet 21 and coolant outlet22, respectively, when cover 19 is placed onto and secured to housingsection 13. Gaskets, fasteners, and other ancillary materials (notshown) may be provided on one or both of surfaces 29, 33, such as forsealing, securing, masking, or otherwise optimizing the engagement ofcover 19 with housing section 13. By such assembly, O-rings 169-173 arecompressed, whereby heat transfer surfaces 178-180 are axially pressedagainst housing axial end surface 33 by the spring force of suchcompression.

FIG. 14 is a perspective view and FIG. 15 is a schematic elevation viewof a power electronics module being clamped to housing axial end surface33, according to an exemplary embodiment. A clamp 183 has a base portion184, an arm 185, and a biasing portion 186. Base portion 184 has anattachment surface 187 that is affixed to housing surface 33 such as bywelding, brazing, adhesion, and/or by other process. A power electronicsmodule 188 includes a spring receiving portion 189, a transfer plate190, a heat generating portion 191, and a heat sink 192. An interfacelayer 193 may optionally be placed between heat transfer surface 194 ofheat sink 192 and housing axial end surface 33. Interface layer 193 mayinclude a mylar sheet for electrically insulating heat sink 192, and mayinclude TIM or another heat transfer material. A spring 195 is placedbetween a spring receiving surface 194 of module 188 and an engagementsurface 196 of clamp 183. For example, spring 195 may be a coil, leaf,elastomer, torsion, helical, snap, Belleville, or other type spring.Power electronics module 188 may include any number of components orother modules. For example, any number of ancillary components 197 suchas connectors may be attached or otherwise incorporated into a modulestructure. When module 188 has been assembled and installed on surface33, clamp 183 urges module against surface 33 with a spring force. Forexample, the assembly and installation may be performed while spring 195is compressed, whereby the combined axial biasing force of clamp 183 andspring 195 urges module 188 against surface 33 and thereby lowers thethermal resistance therebetween.

The spring force being applied to power electronics components and/ormodules may be determined by a spring's dimensions. For example, thelength of a leaf spring or clamp may be proportional to the springforce, and changing the diameter and/or thickness of an O-ring maychange the corresponding spring profile. The material of a given springalso affects the spring force. For example, the durometer hardness of anO-ring is proportional to its spring force.

FIG. 16 is a cross-sectional schematic view of an integrated coolantsystem, according to an exemplary embodiment. Coolant inlet 21 extendsthrough the space between cover 19 and housing section 13, and passesthrough housing section 13. A sealing member 205, for example a gasket,epoxy, rubber sleeve, or other structure, sealingly secures inlet 21 tohousing section 13. Coolant fittings may be brazed or bolted into place.For example, brazing may be used to eliminate additional parts and spacethat would be required when using bolts. A coolant fitting may include amanifold. Coolant inlet 21 has an open end 206 where coolant flows intocoolant channel 207 formed between housing section 11 and housingsection 13. Coolant channel 207 may be formed to be proximate conductorend turns 208 projecting from stator 2. Coolant channel 207 is adjacentpower electronics modules 209, 210 that are mounted to surface 33 ofhousing section 13. A cooling module 211 has a serpentine coil 212formed of sub-miniature thermoplastic or rubber tubing, or formed byjoining together injection molded high temperature plastic sheets. Coil212 has an inlet tube 213 in fluid communication with coolant inlet 21.For example, inlet tube 213 may be sealingly joined to coolant inlet 21at a molded connection 214. Cooling module 211 may be formed as aflexible structure having an adhesive for securing coil 212 to a surfaceof cover 19 and/or to a surface of a power electronics device 215without the need for additional fasteners. Electronics device 212 may beoriented in any chosen manner and may have a heat transfer surfaceattached to serpentine coil 212 by adhesive or by another structure.Serpentine coil 212 may have a fluid outlet 216 configured as aconnector. In such a case, fluid connector 216 may be structured formating with a connector 217 attached to a coolant tube 218. In variousconfigurations, coolant tube 218 may be attached to another coolingmodule, to a cooling channel formed between housing sections 11, 13, toa stator cooling jacket, to coolant outlet 22 (FIG. 3), or to a moldedconnection 219 of coolant inlet 21. When coolant outlet tube 218 ismated to fluid connector 219, cooling module 211 is thereby fluidlyconnected to the main coolant flow as a parallel tap, whereby coolantflow rate and volume through serpentine coil 212 is a fractional partthat may be maintained by a diverting or channeling structure of inlet214. Any number of parallel taps may be formed along coolant inlet 21.Any number of cooling modules 211 may be disposed within cover 19, inany series or parallel combination. For example, modules 211 may bejoined together in a series string that is attached as a parallel tap.In an alternative embodiment, any cooling module 211 may be connected inseries with cooling channel 207. Cooling channel 207 is fluidlyconnected to a coolant transfer passage 220. For example, coolanttransfer passage 220 may transfer coolant to other portions of electricmachine 1, such as to stator cooling jacket 200 (FIG. 4A). Withreference to FIG. 3, baffles 233, 234 are embossed into housing 13.Baffle 233 extends axially along a portion of an exterior housing faceand wraps around an axial end of electric machine 10, whereas baffle 234does not wrap around the axial end. This alternating baffle pattern maybe repeated around the circumference of machine 10. This alternatingbaffle pattern forces coolant to simultaneously flow in a serpentinepath both around the circumference of machine 10 and across the axialend face. For example, coolant may flow out of opening 206, throughcoolant channel 207 across the axial end face in a radially outwarddirection, turn ninety degrees to flow axially toward the other axialend (front) of machine 10 in a channel 220, turn 180 degrees around abaffle 233, 234, flow in an axial direction back toward the coolantinlet end (rear) of machine 10 in a channel 220, turn ninety degrees toflow radially across the axial end face, turn 180 degrees to flow in anopposite direction across the axial end face, etc. A coolant path maythereby be optimized by implementing any axial and radial flow patternsin any series or parallel combination. A coolant path may include bothmodular cooling elements and coolant channels integrated into othermachine structure.

In operation, coolant flow through cooling modules 211 removes heat frompower electronics attached thereto. Many electronics components have amaximum temperature rating between 100° C. and 130° C. Coolant flowthrough coolant channel 207 removes heat from power electronics modules209, 210 attached to surface 33 of housing section 13 and from any powerelectronics devices 198 attached to the inner side of coolant channel207 along a surface of housing section 11. Coolant flow through coolantchannel 207 also removes heat from adjacent stator coil end turns 208.For example, a conductive potting compound or other thermally conductivematerial may be placed in space 221 between end turns 208 and coolantchannel 207 for improving the efficiency of heat transfer therebetween.Typically, the temperature of end turns 208 is much higher than thetemperature of power electronics such as modules 209, 210 and devices198, 215. Therefore, coolant that has been heated by power electronicsis still at a temperature much lower than the temperature of end turns208, so such coolant is effective in removing heat from end turns 208.Accordingly, coolant flow directed at removing heat of end turns 208 istypically downstream of other cooling events.

Any of the disclosed embodiments may be combined with any otherembodiment, for a chosen application. For example, coolant channel(s) 35formed between housing sections 11, 13 may be in fluid communicationwith further coolant routing via bearing assemblies 26, 28. In such acase, for example, a bearing assembly may include a fluid manifold andmay transfer coolant between a non-rotating portion and a rotatingportion, such as for flowing coolant to a rotor. In another example,baffles may be formed in a given section of a coolant path toeffectively slow the coolant flow in proximity of power electronicscomponents, and a downstream section of the coolant path may be formedwithout baffles and have a narrow diameter or cross-section to speed upand/or increase pressure of coolant flow entering a manifold. In afurther example, a bearing assembly support structure formed of sheetmetal may provide a surface for mounting power electronics componentsand/or springs, and may include a coolant flow path. In such a case, thecoolant flow path may be formed in space between housing sections 11,13, by axially extending outer housing section 13 in alignment withaxially extending housing portion 203. Portion(s) of the powerelectronics components may thereby be cooled by a same coolant channelformed as part of a bearing assembly support structure. In variousembodiments, power electronics may be secured in position withconventional structure such as an adhesive layer, such as when spacerequirements do not permit use of a biasing device. The electric machinemay rotate in either the clockwise (CW) or counter-clockwise (CCW)direction. Coolant flow may be assisted by the rotation. Coolant flowmay be partitioned and may include series and/or parallel paths. Invarious embodiments, a power electronics circuit may include peripheraldevices such as circuitry for controlling coolant flow. Such may becombined with a physical partitioning of coolant flow. For example,coolant paths may be formed in modular fashion and/or having paralleltaps for cooling individual electronics modules, and control thereof mayregulate coolant flow to different locations based on operatingtemperature(s).

Although power electronics are herein described in various embodimentsas being mounted as individual components that may be directly biasedagainst a cooling or heat transfer surface, such components mayalternatively be mounted collectively on plate(s) or substrate(s) (notshown) that are spring biased against a cooling jacket or other surfacefor removal of heat therefrom. In many cases, such plate or substratemay be made more readily adaptable for mating with a biasing device suchas a spring, compared with a bare electronics component. As with theillustrated embodiments, TIM may be placed between a surface of theplate or substrate and the cooling jacket surface.

In various embodiments, power electronics components and otherelectronics may be mounted on both sides of a two-sided PCB, may bedistributed at discrete locations and electrically interconnected, maybe partitioned into components located both within and outside of aninternal chamber defined by the housing, and/or they may be partitionedinto components that source little or no heat and components requiringheat sinking with associated structure such as TIM and spring typebiasing members. By distributing electronics components, packaging maybe maximized while simultaneously maximizing heat rejection.

While various embodiments incorporating the present invention have beendescribed in detail, further modifications and adaptations of theinvention may occur to those skilled in the art. However, it is to beexpressly understood that such modifications and adaptations are withinthe spirit and scope of the present invention.

What is claimed is:
 1. An electric machine, comprising: inner and outerhousing sections attached to one another to form, at an axial end of theelectric machine, a cooling channel therebetween; a bearing carriercoupled to the housing sections and radially registered to the insidediameter of the inner housing section.
 2. The electric machine of claim1, wherein the bearing carrier includes the inner housing section. 3.The electric machine of claim 2, further comprising a bearing assembly,wherein the inner housing section includes an annular,axially-inward-extending portion structured for radially enclosing thebearing assembly.
 4. The electric machine of claim 3, wherein theaxially-inward-extending portion of the inner housing is mated to thebearing assembly by a keying structure.
 5. The electric machine of claim3, wherein the annular, axially-inward-extending portion of the innerhousing section includes an annular flange for retaining an axiallyinward end of the bearing assembly.
 6. The electric machine of claim 1,further comprising an annular ring structured for retaining an axiallyoutward end of the bearing assembly.
 7. The electric machine of claim 6,wherein the bearing carrier includes the annular ring.
 8. The electricmachine of claim 6, wherein the annular ring comprises a coil.
 9. Theelectric machine of claim 6, wherein the annular ring is secured to theinner housing section.
 10. The electric machine of claim 1, wherein thebearing carrier is axially registered with the inner housing section.11. The electric machine of claim 1, wherein the bearing carrier isaxially registered with a stator assembly.
 12. An electric machine,comprising: annular, L-shaped inner and outer sheet metal housingsections enclosing a cooling channel at an axial end of the electricmachine and otherwise being substantially parallel and contiguous; and afirst bearing assembly coupled to the inner housing section.
 13. Theelectric machine of claim 12, further comprising an annular bearingcarrier attached to the inner housing section for securing the firstbearing assembly.
 14. The electric machine of claim 13, furthercomprising a first axial end cover structured for axially retaining thebearing carrier.
 15. The electric machine of claim 14, furthercomprising at least one fastener for securing the first axial end coverto the housing sections proximate the bearing carrier and therebyradially supporting the bearing carrier.
 16. The electric machine ofclaim 13, wherein the bearing carrier is secured to the inner housingsection by a keying structure.
 17. The electric machine of claim 12,further comprising an annular sealing structure engaging the bearingassembly and the inner housing section.
 18. The electric machine ofclaim 17, wherein the sealing structure includes an O-ring.
 19. Theelectric machine of claim 12, further comprising: a second bearingassembly; and a second axial end cover attached at the other axial endof the electric machine, the second axial end cover having an annular,axially-inward-extending portion structured for radially enclosing thesecond bearing assembly.
 20. The electric machine of claim 19, whereinthe annular, axially-inward-extending portion of the second axial endcover includes an annular flange for retaining an axially inward end ofthe second bearing assembly.